SB4267E00

May. 2007

Vehicle System
Disassembly & Assembly

D35S-5, D40S-5, D45S-5, D50C-5, D55C-5

D40SC-5, D45SC-5, D50SC-5, D55SC-5
G35S-5, G40S-5, G45S-5, G50C-5, G55C-5
G40SC-5, G45SC-5, G50SC-5, G55SC-5
GC35S-5, GC40S-5, GC45S-5
GC50C-5, GC55C-5

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 Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards. This person should also have the
necessary training, skills and tools to perform these functions properly.

Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.

Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific
hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
Warnings in this publication and on the product labels are identified by the following symbol.

WARNING

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in
injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.

Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.

DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DOOSAN dealers have the most current
information available.

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 Index

Disassembly & Assembly....................... 5

Hood (with seat) .................................................... 5

Overhead Guard.................................................... 6
Tilt Cylinders ......................................................... 7
Secondary Lift Cylinders........................................ 9
Primary Lift Cylinder ............................................ 12
Hydraulic Control Value ....................................... 15
Washing .............................................................. 17
Inspection............................................................ 17
Assembling.......................................................... 18
Relief Valve Maintenance .................................... 20
Steering Wheel.................................................... 29
Steering Unit ....................................................... 30
Brake Hydraulic Booster ...................................... 39
Tie Rods.............................................................. 43
Steering Knuckles, Kingpins, And Bearings ....... 44
Steer Axle............................................................ 45
Steering Cylinder ................................................. 46
Tires And Rims (Steer) ........................................ 48
Hydraulic Control Valves...................................... 49
Hydraulic Pump ................................................... 50
General Instruction .............................................. 51
Disassembly Process .......................................... 51
Counterweight ..................................................... 56
Hydraulic Oil Filter Assembly ............................... 57
Drive Axle and T/M .............................................. 57
Engine................................................................. 58

WARNING
Disconnect batteries before performance of any
service work.

Vehicle Systems 3 Index

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 Disassembly & Assembly
3
Hood (with seat)
Remove & Install Hood (with seat)
Assembly

5. Remove the washers and four bolts (3).

1

WARNING
The hood and seat assembly can fall when nut
(1) is removed from the support cylinder rod. To
avoid personal injury, support the seat and hood
assembly before removing nut (1).
6. Release latch (4). Use the hoist to remove hood
1. Raise the hood. Support the hood with a hoist.
and seat assembly. The hood and seat assembly
weighs approximately 52 kg (115 lb).
2. Remove nut (1) from the support cylinder.
Remove the cylinder rod from the bracket. 7. Install the hood and seat assembly in the reverse
order of removal.
3. Lower the hood.

4. Remove the bolts (2) from the cover. Remove

cover.

Vehicle Systems 5 Disassembly & Assembly

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 Overhead Guard
Remove & Install Overhead Guard

3. Remove the washers, nuts, and two bolts (3).

4. Remove front overhead guard (1), Front overhead

guard (1) weighs approximately 30 kg (66 lb).

1. Support overhead guard (1) with lifting straps and

5. Remove the washers, nuts, and four bolts (4).
a hoist.
6. Remove rear Leg (5).

7. Install front overhead guard (1) and rear leg (5) in

the reverse order of removal.

2. Remove the washers, nuts, and two bolts (2).

Vehicle Systems 6 Disassembly & Assembly

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 Tilt Cylinders
Remove & Install Tilt Cylinders

NOTE: The procedure for removing and installing

the tilt cylinders is the same for both cylinders.

WARNING
If both tilt cylinders are removed at the same
time the mast can fall. To avoid possible
personal injury, make sure the mast is securely
held in place or supported by a hoist before
2. Remove retainer bolt (6) from pin (5). Remove pin
removing the tilt cylinders.
(5).

3. Remove tilt cylinder (4).

4. Install the tilt cylinder in the reverse order of

removal.

WARNING
To prevent personal injury, move the control
levers backward and forward to release any
pressure in hydraulic system. Slowly loosen the
cap of the hydraulic tank to release any pressure
in the tank. Be cautious of hot hydraulic oil when
any lines are disconnected in the hydraulic
system.

1. Disconnect elbow (2). Remove retainer bolt (3)

and pin (1).

Vehicle Systems 7 Disassembly & Assembly

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 Disassemble & Assemble Tilt Cylinders

Start By:

a. Remove tilt cylinder.

4. Remove pin (5) inside hole and nut (6) from the
cylinder rod (4).

5. Remove piston (7) from the cylinder rod.

1. Remove eye (1) from the rod assembly (4).

6. Remove O-ring seal (8) from the cylinder rod.

2. Remove rod cover (2) from the cylinder tube (3)

using a spanner wrench.

NOTICE
Use extra care not to damage the highly finished
surface of the cylinder rod and the bore of the
clylinder tube during disassembly and assembly of
the tilt cylinder.

3. Remove rod assembly (4) from the cylinder body.

7. Remove wear ring (9) and slipper seal (10) from
the piston.

Vehicle Systems 8 Disassembly & Assembly

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 Secondary Lift Cylinders
Disassemble Secondary Lift Cylinders

Start By :

a. Remove secondary lift cylinders.

8. Remove O-ring seal (11) and backup ring (12)

from the rod cover (2).

1. Put secondary lift cylinder (1) in position as shown.

9. Remove wiper seal (13), backup ring (14), U-

packing (15) and DU-bush (16) from the rod cover.

NOTE: Assemble the tilt cylinder in the reverse

order of disassembly.

2. Remove head assembly (2) with tool.

3. Remove rod (3) from the cylinder body.

Vehicle Systems 9 Disassembly & Assembly

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 4. Remove retaining ring (4) and piston (5) from the 7. Remove O-ring seal (10) from the head assembly.
cylinder rod.

5. Remove O-ring seal (6) from the cylinder rod. 8. Remove wiper seal (11), seal (12) and bush (13)
from the head assembly.

6. Remove O-ring seal (7), back-up ring (8) and seal

(9) from the piston.

Vehicle Systems 10 Disassembly & Assembly

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 Assemble Secondary Lift Cylinders

5. Install O-ring seal (6) on the cylinder rod.

1. Install bush (13) and seal (12).

2. Install wiper seal (11). Install the seal with the lip
toward the outside.

6. Install piston (5) and retaining ring (4) on the

cylinder rod.

3. Install O-ring seal (10) onto the head assembly.

7. Install cylinder rod (3) in the cylinder body.

4. Install seal (9), back-up ring (8) and O-ring seal

(7) on the piston.

Vehicle Systems 11 Disassembly & Assembly

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 8. Install head assembly (2) on the cylinder rod and 1. Fasten nylon straps and hoist to the primary lift
tighten using tool. cylinder.

End By : 2. Remove bolt (1).

a. Install secondary lift cylinders.

Primary Lift Cylinder

Remove & Install Primary Lift Cylinder

Start By :

a. Remove carriage.
3. Pull the cylinder out far enough to disconnect
hydraulic hose (2). Remove primary lift cylinder
WARNING (3).
To prevent personal injury, move the control
4. Install primary lift cylinder (3) in the reverse order
levers backward and forward to release any
of removal.
pressure in hydraulic system. Slowly loosen the
cap of the hydraulic tank to release any pressure
End By :
in the tank. Be cautious of hot hydraulic oil when
any lines are disconnected in the hydraulic
a. Install carriage.
system.

Vehicle Systems 12 Disassembly & Assembly

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 Disassemble Primary Lift Cylinder

Start By :

a. Remove primary lift cylinder.

4. Remove O-ring seal (4) and back-up ring (5) from

the bearing.

1. Remove bearing (1).

2. Remove rod (2) from the cylinder body.

5. Remove wiper seal (6), back-up ring (7), seal (8)

and rings (9) from the bearing.

3. Remove split rings (3) from the cylinder rod.

Vehicle Systems 13 Disassembly & Assembly

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 Assemble Primary Lift Cylinder

5. Install split rings (3) on the cylinder.

1. Install back-up ring (7) and seal (8) in the bearing.

Install the seal with the lip toward the inside.

2. Install wiper seal (6). Install the seal with the lip
toward the outside.

3. Install rings (9) in the bearing.

6. Install cylinder rod (2) in the cylinder body.

7. Install bearing (1) on the cylinder body. Tighten

the bearing (1).

End By :

a. Install primary lift cylinder.

NOTE: Install the back-up ring with the curved side
contacting the O-ring seal.

4. Install the back-up ring (5) and O-ring seal (4) on

the bearing.

Vehicle Systems 14 Disassembly & Assembly

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 Hydraulic Control Value 2. Slowly remove each spool section assembly in
the reverse order as in the outlet section.
Take care not to lose poppet, springs, or o-rings in
Disassembling the fitting face of each section.
Keep following precautions for disassembling.
3. Remove the tie rods (2) & (4) from the inlet
section assembly.
1. The main equipment has to be leveled, with all
the working units grounded, engine stopped, and
the actuator has to be depressurized. If
Disassembling the Inlet Section
disassemble the actuator while it is pressurized, Assembly
high pressure oil or part may ejected out which is
very dangerous. The combination number shall be in accordance
with the attached Part List No. C0213-41001.
2. Release the air pressure in tank(for pressurized
tanks) Fix the unit on the vise softly, covering the fitting
face of the inlet section assembly to prevent
3. Clean up the surroundings of the part to be damage.
disassembled, and take care that foreign matter
does not enter the valve. 1. Remove socket head bolt(14), remove cap(13),
and remove the spool(2) in sub-assembly state
4. Mark the disassembled parts or arrange them on from the inlet housing(1). The seal plate(5),
work bench in the order of assembly in order not wiper(4), and O-ring(3) on the cap(13) side have
to confuse the order of assembling. to be remain affixed to the spool(2)

5. Replace all the seals(O-rings, back-up rings)

which were disassembled with new seals. 【Cautions for Removing Spool 】
When removing the spool, take it out correctly to
6. Since the spool is matched with the valve housing prevent dent or scratch. Dent or scratch may harm
by clearance control, it is not replaceable for the housing hole when removing the spool, or may
quality. Protect it from impact of falling down. make it impossible to reinsert the spool, or may
cause malfunction even able to be inserted. Each
7. Protect the sealing faces of the fitting surfaces in spool has to be marked and arranged on work
all sections from impact or scratch. bench, etc., to prevent confusion in reassembling. If
assembled wrong, the actuator will fail to operate
8. In order to minimize internal leak, the clearance of properly, which may cause serious danger.
spool is kept as small as possible. Disassembling
and assembling the spool may deform the spool.
Therefore, full assembly replacement, when
necessary, is recommended.

Refer to the attached Parts List for the dimensions

and torques of the screws and plugs related with the
disassembling.

Disassembling Valve Assembly

The assembling number shall be in compliance with

the attached Assembly Parts List: Representative
Parts No. C0240-41001.
【Fig. 2 – 1 】
1. Place the valve assembly on level work table, with
the mounting side down. Remove the nuts(1) and
(3) for the tie rod, at the end of the outlet section.

Vehicle Systems 15 Disassembly & Assembly

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 2. Hold the spool (2) on a vise by inserting rigid 11. Take out plug(34) and remove spring(33) and
wood pieces(Fig. 2-1) etc. to prevent damage on poppet assembly(32).
the surface. Remove the cap screw(11), Then, remove the main poppet from the poppet
disassemble spring seat(7) and spring(6), and assembly(32).
remove wiper(4) and O-ring(3). At this time, take The poppet assembly was described as the
care that cap screw or other parts are not ejected unload valve in the Operation Section earlier.
out by the spring force.
12. Take out the two plugs (42) and (59).
3. Remove the screw(15) on the spool head, remove These three plugs are only for open/close,
the seal plate(5), wiper(4) and O-ring(3). without internal sub-parts. Therefore, do not
disassemble them except when necessary.
4. Unscrew and remove the solenoid valve (24）,
remove spring(22) and poppet(21). 13. Finally, remove the O-rings and wipers on each
disassembled part.
5. Take off plug(18), and remove spring(17) and
poppet(16). Disassembling the Spool Section
Assembly for Tilting
6. Unscrew the lock nut on the shut-of valve(20).
Turn the set screw by 1 or 2 turns and take it off The combination No. shall be in accordance with the
inwardly, and take out the main body of the shut- attached Part List (Part No.: C0213-41201).
off valve. Fig. 2-2 is the detail drawing.
7. Remove the socket head bolt(40), take out the
solenoid(38). Since an O-ring is mounted on the
in-low part of the solenoid providing large friction
force, do not apply excessive force to twist it.
Remove shuttle(36) and spring(37) from inside to
outside.

8. Unscrew the two relief valve assemblies(41) and

remove them from the assembly.
Though the two valves are identical in appearance,
however, since the pressure settings for the main
relief and second relief valves are different, mark
the two relief valves for distinguish them.

【Cautions for Disassembling the Relief Valve】

In principle, the relief valve has to be replaced in
assembly unit. Therefore, do not disassemble it
except when necessary. If it is necessary to
disassemble, refer to the Relief Valve Maintenance
Manual. Mark each part for identification in
assembling.
1. Take out the O-rings(12) & (18) from the fitting
9. Take out plug(52), remove spring(51) and surface, remove spring(11) and poppet(10).
spool(50).
2. Unscrew the socket head bolt(14) and take out
10. Take out plug(30) and remove spool(26) and the cap(6).
spring(27) in assembly state. Take out the spool(2) in sub-assembled state from
Hold the sub-assembled spool(26) with a vise the valve housing(1). At this time, remove the seal
using rigid wood pieces(Fig. 2-1) to prevent plate(3), wiper(5) and O-ring(4), on the cap side,
damage on spool surface. Take out plug(29) and as mounted on the spool(2).
remove the check valve(28) from inside.
3. Loosen the screw(13) on the opposite side,
remove seal plate(3), wiper(5), and O-ring(4).

Vehicle Systems 16 Disassembly & Assembly

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 4. Hold the spool(2) in a vise using rigid wood Washing
pieces(Fig. 2-1) to prevent damage. Remove cap
screw(8) and remove spring seat(7), spring(9), Wash all the disassembled parts completely with
wiper(5) and O-ring(4). At this time, take care that mineral oil.
cap screw or other parts are not ejected out by the Dry the washed parts with compressed air and
force of the spring(9). arrange them on clean paper or cloth for inspection.
5. Remove spring(16) from inside the spool(2).
Remove the valve(15) from the spool(2) by Inspection
unscrewing the M4 screw at its end.
Inspect all the parts if they have any burr, scratch,
Disassembling the Spool Section dent, or any other defect.
Assembly for Attachment
1. Confirm that the spool surfaces are free from
scratch or dent.
The combination shall be in accordance with the
Small scratch can be removed with oil stone or
attached Parts List(Part No. C0213-41202).
cloth with lapping material.
The disassembling of the Part No. C0213-41203 in
2. Reciprocating parts must move smoothly. All the
the attached Parts List is same as this section,
holes and paths must be free from foreign matter.
therefore, not described.
3. Worn, deformed, or broken spring must be
1. Remove O-rings(12), (18) from the fitting surface,
replaced.
and remove spring(11) and poppet(10).
4. Check that the sealing face of the valve housing
2. Unscrew socket head bolt(15) and remove cap(6).
is smooth, free from dust, rust, or dent.
Take out the spool(2) from the valve housing(1) in
sub-assembled state. At this time, remove seal
5. Remove any dent or scratch on the check valve
plate(3), wiper(5) and O-ring(4) on the cap side as
seat of valve housing by lapping. Take care not to
mounted on the spool.
leave any lapping material in the valve.
3. Remove the screw(13) on the opposite side.
6. If relief valve is not in normal order, inspect it in
Remove seal plate(3), O-ring(4) and wiper(3).
compliance with the Relief Valve Maintenance
Manual.
4. Hold the spool(2) in a vise using rigid wood
pieces(Fig. 2-1) to prevent damage. Remove cap
7. Replace all the O-rings and back-up rings with
screw(8) and remove spring seat(7), spring(9),
new ones.
wiper(5) and O-ring(4). At this time, take care that
the cap screw or other parts are not ejected out by
8. Check that there is no residual coating debris
the force of the spring(9)
around the housing holes and plug seats.
In the event that coating debris is in the valve, it
The disassembled parts have to be arranged in
will cause malfunction and oil leak.
order to identify their assembly position on work
bench, shelf, etc.

Vehicle Systems 17 Disassembly & Assembly

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 Assembling Spool Subassembly

Take following cares when handling the O-rings. With reference to the attached Part List of each
section assemblies, mount O-ring, wiper and seal
1. Do not use any defective O-ring, whether the plate on the spool in specified order. Insert spring
defect was made in forming or handling, between the spring seats and mount it on the spool
with cap screw.
2. Apply grease or hydraulic oil on O-ring and their Hold the spool in a vise with rigid wood pieces (Fig.
seats for full lubrication 2-1) to prevent damage during assembling. Apply
grease around the spring.
3. Do not stretch O-ring severely. Otherwise, it may As shown in Fig. 5-1, the wiper must be mounted
be deformed. with the protruded part facing outwards.
Be careful that the valve and spring are inserted in
4. Do not roll-in the O-ring when mounting it. the hollow space of the tilt spool only.
If O-ring is twisted, it may cause oil leak.

Take following cares when handling the spool. Protrusion

O-ring
1. Keep specified torque. Excessive torque will
Wiper
cause malfunction of spool.

2. Take care that the spool, spring, and cap screws

are combined in the same assembly as they were
before the disassembling.
Spool

Take following cares when assembling section Valve Hosing

Seal Plate
assembly and valve assembly.
Seal Hole
1. O-rings in the fitting face must not protrude out.
【Fig. 5－1】
2. Before assembling, following points must be free
from any washing or hydraulic oil.

・Fitting faces of each section, outside of O-ring

grooves.

・Capping surfaces, outside the O-ring grooves.

If oil is left at above points, it may be mistaken
as the oil leak.

Assembling the Valve Housing

1. Assemble poppet(10), spring(11), O-rings(12),

(15) or (18) on each section surface.

2. Insert the tie rods(2), (4) (P/N C0240-41001,

attached Parts List) to fix them in the inlet section.
Assemble the valve housings of each section in
correct order. Finally, assemble the outlet housing.
On the tie rod, tighten nuts(1), (3) to specified
torque. Take care that the spring(11) on the fitting
surface does not hinder.

Vehicle Systems 18 Disassembly & Assembly

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 Assembling Inlet Section Assembly 7. Insert shuttle(36) into spring(37) and insert them
into inlet hosing(1).
Combination number shall be in accordance with the At this time, the shuttle(36) may be ejected out by
attached Part List (P/N: C0213-41001). spring(37) force. Place the solenoid(38) on the
Tightening torque of each part shall be in end of the shuttle, slowly insert them into the
compliance with the Parts List. position where they will not come out by the
friction of the O-ring in the in-low part, and tighten
with socket head bolt.

Orifice F

Coil Dia.

【Fig.5-2】

1. Mount O-rings and wipers on each plug. 8. Insert poppet into the main body of the shut-off
valve (20), mount them on the inlet housing(1).
2. If the two plugs (42) and (59) were removed, And then tighten with set screw. Finally, join lock
tighten them at the original position. nut onto the set screw.

3. Insert the main poppet into the poppet (unload 9. Insert spring(17) into poppet(16).
valve) to make the poppet assembly(32), and Make sure to insert the larger diameter part of the
insert it into the inlet housing(1). spring(17) into the poppet as shown in.
Then, insert the spring(33) into the main poppet, If assembled in opposite, the spring may be
and tighten the plug(34) making sure that its end broken.
is inserted in the inside of the spring(33). Insert the poppet(16) inserted with spring(17)
Into plug(18), tighten to the inlet housing(1) so
4. Take care when assembling the spool(26) that the Poppet(16).
because the valve(28) is directional.
As shown in【Fig.5-2】, assemble with the orifice 10. Insert poppet(21) and spring(22) into inlet
Ｆ inside the plug(29), and insert the plug(29) into housing(1). Tighten by turning the solenoid valve.
the spool(26).
Then, while holding the spool(26) in a vise with 11. Assemble O-ring(3) and wiper(4) in the seal hole
rigid wood pieces(Fig. 2-1) to prevent damage, on the spool head side of inlet housing(1). Fix
tighten the plug(26). the seal plate(5) with screw(15).
Finally, insert the spring(27) into the sub-
assembled spool(26), insert it into the inlet 12. Finally, insert the sub-assembled spool(2) from
housing(1) and tighten the plug(30). the opposite side of the inlet housing(1), cover
with cap(13), and tighten with screw(15).
5. Insert spring(51) into the spool(50), tighten
plug(52). 【Cautions For Inserting Spool】
Insert the spool slowly, vertically to the axis of the
6. Assemble two relief valve assemblies (41) in the hole. Reciprocate the spool with hands to check if
original mounting ports. Take care not to confuse there is any resistive or uneven feeling which may
the position. cause malfunction of the spool.

Vehicle Systems 19 Disassembly & Assembly

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 Assembling Spool Section Assembly Relief Valve Maintenance
The combination numbers shall in accordance with Main Relief Valve, Second Relief Valve
the pertinent Parts List.
Tightening torques of each part must be in Disassembling
compliance with the Parts List.
The combination numbers shall be in accordance
1. Assemble O-ring(4) and wiper(5) in the seal hole with the attached Part List(P/N: C0003-30020) and
on the spool head side of the valve hosing (1). Fix Fig. 6-1.
the seal plate(3) with screw(15).

2. Insert the sub-assembled spool(2) from the

opposite side of the valve hosing(1). Cover with
cap(6) and fix with screw(13).

Confirmation of Assembly Work

【Cautions for Assembling Work】

Check if there is any unassembled, missing part
after assembling. Missing part may cause oil leak.

Pressure Adjustment after Assembling

As shown in the main relief valve and second relief

valve(Fig. 6-1), loosen the adjust kit(5) to release
pressure in all the circuits. Set the engine at the
rated rpm, block the circuit and slowly adjust the Loosen the lock nut on the adjust kit (5) and remove
pump port pressure to be the set pressure indicated Spring (3) and pilot poppet (2) from the plug (4).
in the drawing, with the adjust kit(39). When Since the pilot seat (1) has a hole at the end of the
adjusted, tighten and lock with nut. Plug, do not disassemble it.

【Cautions for Disassembling Relief Valve】

Relief valve has to be replaced in assembly unit, in
principle. Do not disassemble it unless necessary.
The main poppet is built in the unload valve, as
described in the paragraph 1.2.

Vehicle Systems 20 Disassembly & Assembly

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 Washing, Inspection 5. At the specified pressure, hold the adjuster and
tighten with lock nut. Specified torque: 27～31Ｎ
Wash all parts with clean mineral oil. Dry with ・ｍ
compressed air for inspection.
6. Raise the pressure again to check if the specified
1. The poppet seats and plugs must be free from pressure is obtained
defect and smooth.
Note: When the main and second relief valves are
2. Main poppet and unload valve must be able to operated simultaneously, the setting pressure of the
reciprocate lightly and smoothly. main relief valve takes the precedence.
Outside of the main poppet and the inside of the
unload valve must be free from scratch or damage. Installation

3. Spring (3) must be free from fracture, deformation Take following cares at installation
or wear.
・Pipe line must not exert unnecessary force to
4. The main poppet and pilot seat(1) holes must be valve.
free from foreign matters.
・Mounting bolts must be tightened with same
5. O-rings and back-up rings must be replaced with torque.
new ones.
If allowable scratch is identified, remove it by ・Welding work near valve may damage the seals
lapping. by excessive heat or scatter.
If any part is found to be defective, replace with a
new relief valve assembly. ・Do not uncover valve ports until piping connection
to prevent dust from coming in.
Assembling
Operation
1. Mount O-ring and back-up ring on the pilot seat(1)
and adjust kit(5). ・Valve arrangement must be in correct order.
Check that the hydraulic oil is clean, raise
2. Insert poppet(2) and spring(3) into the plug(4), pressure slowly(inching operation at low idle),
and temporarily assemble the adjust kit(5) confirm that there is no external oil leak.
mounted with O-ring.
・Use hydraulic oil of which the annealing point is
3. Insert into the inlet housing and adjust the 82～113℃.
pressure.
・Do not raise the pressure in the relief valve higher
Assembling work of main poppet shall be in than the specified setting pressure
compliance with the paragraph 5.3.
・Make sure to provide sufficient warming up of the
Note:Ｏ-rings and back-up rings must be replaced machine before operation.
with new rings, not reused.
Especially, when starting up while the temperatures
Pressure Adjustment of the hydraulic oil and valve is cold, take following
cares to prevent sticking of the spool by thermal
1. Install an accurate pressure gauge at the circuit shock.
inlet
・Do not operate the main and second relief valves
2. Operate the pump at the rated rpm successively during the warming up operation.
Circulate the hydraulic oil in the actuators to raise
3. Replace the spool of the control valve, read the temperature of all the parts evenly.
pressure gauge at the end of the cylinder stroke.
・Inching operation or composite operation may
4. Turn the adjuster clockwise until desired pressure cause local heating, therefore, must not be carried
is reached. out while the system is cold.
Each turn of adjuster will raise 17.7MPa of
pressure ←（reference value）

Vehicle Systems 21 Disassembly & Assembly

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 Ref.No. GZ-MS-V0030

Assembly Parts No.：Represent Item No.Ｃ０２４０－４１００１

Vehicle Systems 22 Disassembly & Assembly

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 Ref.No. GZ-MS-V0030

Vehicle Systems 23 Disassembly & Assembly

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 Ref.No. GZ-MS-V0030

Vehicle Systems 24 Disassembly & Assembly

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 Ref.No. GZ-MS-V0030

Vehicle Systems 25 Disassembly & Assembly

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 Ref.No. GZ-MS-V0030

Vehicle Systems 26 Disassembly & Assembly

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 Ref.No. GZ-MS-V0030

Vehicle Systems 27 Disassembly & Assembly

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 Ref.No. GZ-MS-V0030

Vehicle Systems 28 Disassembly & Assembly

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 Steering Wheel
Remove & Install Steering Wheel

1. Remove cap (1) from the steering wheel.

2. Remove nut (2) and washer (3) from the steering

wheel shaft. Put location marks on the steering
wheel and the steering wheel shaft for installation
purposes.

3. Remove the steering wheel from the shaft.

NOTE: Use the following steps to install the

steering wheel.

4. Put the steering wheel on the steering wheel

shaft in its original position.

5. Install washer (3) and nut (2). Tighten nut (2) to a

torque of 80 ± 7 N•m (60 ± 5 lb•ft).

6. Install cap (1).

Vehicle Systems 29 Disassembly & Assembly

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 Steering Unit 1. Disconnect (4) tubes and (1) hose assembled to
steering unit.
Remove & Install Steering Unit
3
Start By:

a. Remove covers from steering wheel group

1

WARNING 2
.
To prevent personal injury be sure pressure in
the hydraulic system has been released before
disconnecting any hydraulic lines. Slowly
loosen the cap of the hydraulic tank to release
any pressure in the tank. Be cautious of hot
hydraulic oil when any lines are disconnected 2. Remove four bolts (1).
in the hydraulic system.

NOTICE
NOTE: Identify and mark all hydraulic hoses for Steering unit (2) and column (3) can separate after
purposes of reassembly. bolts (1) have all been removed, causing unit (2) to
fall. To avoid damaging components, support the
steering pump while removing bolts (1).

3. Support steering unit (2) while removing the

remaining two bolts (1). Remove steering unit (2).

4. Install the steering unit in the reverse order of

removal.

End By :

a. Install the cover on steering wheel group.

Vehicle Systems 30 Disassembly & Assembly

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 Disassemble Steering Unit

Cleanliness is extremely important when repairing a

steering unit. Work in a clean area. Before
disconnecting lines, clean port area of unit thoroughly.
Use a wire brush to remove foreign material and
debris from around exterior joints of the unit.

Although not all drawings show the unit in a vise, we

recommend that you keep the unit in the vise during
disassembly. Follow the clamping procedures
explained throughout the manual.

End Cap Cap Screw

Seal
Gerotor (Meter) End

IDCD279S

2. Remove 5/16 inch cap screws and washers if

applicable (7 each).

3. Remove end cap.

4. Remove seal from end cap.

Seal

IDCD278S

1. Clamp unit in vise, meter end up. Clamp lightly

on edges of mounting area. Use protective
material on vise jaws. Housing distortion could
result if jaws are overtightened.
Spacer(s)

IDCD280S

5. Remove meter. Be careful not to drop star.

6. Remove seal from meter.

7. Remove drive spacer(s).

Vehicle Systems 31 Disassembly & Assembly

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 Seal Gland
Bushing

Spacer Plate

Drive
IDCD283S
Seal
12. Rotate spool and sleeve until pin is horizontal.
Push spool and sleeve assembly forward with
IDCD281S your thumbs just far enough to free gland
bushing from housing. Remove bushing.
8. Remove drive.

9. Remove spacer plate.

10. Remove seal from housing.

Control End
Quad
Ring
Seal
Seal
Dust Gland
Seal Bushing

IDCD284S

13. Remove quad ring seal from seal gland bushing.

14. Use a thin bladed screwdriver to pry dust seal

IDCD282S from seal gland bushing. Do not damage
bushing.
11. Remove housing from vise. Place housing on a
clean soft cloth to protect surface finish. Use a
thin bladed screwdriver to pry retaining ring
from housing.

Vehicle Systems 32 Disassembly & Assembly

Downloaded from www.Manualslib.com manuals search engine Bearing

 Needle Bearing
Thrust Race
Bearing

Bearing
Race

IDCD285S IDCD287S

15. Remove 2 bearing races and the needle thrust 18. Push spool partially from control end of sleeve,
bearing from spool and sleeve assembly. then remove 4 centering springs from spool
carefully by hand.

19. Push spool back through and out of sleeve.

Rotate spool slowly when removing from sleeve.

20. Remove seal from housing.

Seal

Pin

IDCD286S

16. Remove spool and sleeve assembly from 14

hole end of housing.
Check Ball
Check Ball Seat
ATTENTION: Do not bind spool and sleeve in housing.
Rotate spool and sleeve assembly slowly when
IDCD288S
removing from housing.
21. Remove check ball seat.
17. Push pin from spool and sleeve assembly.
22. Tip housing to remove check ball.

Vehicle Systems 33 Disassembly & Assembly

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 Assemble Steering Unit

Check all mating surfaces. Replace any parts that

have scratches or burrs that could cause leakage.
Spring Slot
Clean all metal parts in clean solvent. Blow dry with air. Control Sleeve
Do not wipe dry with cloth or paper towel because lint
or other matter can get into the hydraulic system and Spring Slot
cause damage. Do not use a coarse grit or try to file or
grind these parts.
Identification Control
Marks Spool
NOTE: Lubricate all seals with clean petroleum jelly
such as Vaseline.
IDCD290S
Do not use excessive lubricant on seals for meter
section. 6. Assemble spool and sleeve carefully so that the
Refer to parts listings covering your steering unit when spring slots line up at the same end. Rotate spool
ordering replacement parts. A good service policy is to while sliding parts together. Some spool and
replace all old seals with new seals. sleeve sets have identification marks, align these
marks. Test for free rotation. Spool should rotate
smoothly in sleeve with finger tip force applied at
splined end.

Check Ball
Seat

Check Ball

IDCD289S

IDCD291S
1. Use a needle nose pliers to lower check ball
retainer into check valve hole of housing. Make
sure retainer is straight (not tilted on edge) in 7. Bring spring slots of both parts in line and stand
housing. parts on end of bench. Insert spring installation
tool through spring slots of both parts. Position 2
2. Install check ball in housing pairs of centering springs on bench so that
extended edge is down and arched center
3. Lubricate 9.3 mm [.36 in.] ID seal and 7.7 mm section is together. In this position, insert one end
[.30 in.] ID seal. Install seals on check ball seat of entire spring set into spring installation tool,
as shown. with spring notches facing sleeve.

4. Lubricate check ball seat and seals thoroughly 8. Compress extended end of centering spring set
before installing seat in housing. When installing and push into spool sleeve assembly withdrawing
seat do not twist or damage seals. Install check installation tool at the same time.
ball seat in housing, insert open end of seat first.
Push check ball seat to shoulder of hole. 9. Center the spring set in the parts so that they
push down evenly and flush with the upper
5. Install set screw. Use a 1/4 inch hex key to surface of the spool and sleeve.
torque set screw to 11 N·m [100 lb·in]. To prevent
interference make sure top of set screw in slightly 10. Install pin through spool and sleeve assembly
below housing mounting surface. until pin is flush at both sides of sleeve.

Vehicle Systems 34 Disassembly & Assembly

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 Needle
Thrust
Bearing Bearing
Race(2
)
Pin
Seal

IDCD292S

11. Position the spool and sleeve assembly so that

the splined end of the spool enters the 14 hole
end of housing first.
IDCD293S
ATTENTION: Be extremely careful that the parts do
not tilt out of position while inserting. Push parts 12. Place housing on clean lint free cloth. Install
gently into place with slight rotating action, keep pin 47.5 mm [1.86 in.] ID seal in housing.
nearly horizontal. Bring the spool assembly entirely
within the housing bore until the parts are flush at 13. Install 2 bearing races and the needle thrust
the meter end or 14 hole end of housing. bearing in the order shown.
Do not pull the spool assembly beyond this point to
prevent the cross pin from dropping into the 14. Install 25 mm [1 in.] ID dust seal in seal gland
discharge groove of the housing. With the spool bushing, flat or smooth side must face down
assembly in this flush position, check for free towards bushing.
rotation within the housing by turning with light
finger tip force at the splined end. 15. Install the quad ring seal in seal gland bushing.
Smooth seal in place with your finger. Do not
use any seal that falls freely into pocket of
bushing.

Vehicle Systems 35 Disassembly & Assembly

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 Retainin
g Ring
Seal
Gland
Bushing
(with seals)

IDCD294S IDCD296S

16. Install seal gland bushing over the spool end 18. Clamp housing in vise. Clamp lightly on edges of
with a twisting motion. Tap the bushing in place mounting area. Do not over tighten jaws.
with a rubber hammer. Make sure the bushing is
flush against the bearing race. NOTE: Check to insure that the spool and sleeve are
flush or slightly below the 14 hole surface of the
housing.

ATTENTION: Clean the upper surface of the housing

Screwdriver
by wiping with the palm of clean hand. Clean each of
Dust Seal
the flat surfaces of the meter section parts in a similar
Retaining way when ready for reassembly. Do not use cloth of
Ring
Seal Gland
paper to clean surfaces.
Bushing

Quad Ring

Seal

IDCD295S

17. Install retaining ring in housing. After installing

ring, tap on ring end or pry with screwdriver
around entire circumference of ring to properly IDCD293S
seat ring in groove.
19. Install 73.5 mm [2.89 in.] ID seal in housing.

20. Install spacer plate. Align bolt holes in spacer

plate with tapped holes in housing.

Vehicle Systems 36 Disassembly & Assembly

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 Seal Groove this Side of Gerotor (Meter)

Star Valley A

B
Port Face Drive
Pin Parallel Drive
with Port (Marked) C
Face
D

Pin

IDCD298S

21. Rotate spool and sleeve assembly until pin is

parallel with port face. Install drive, make sure Pin
you engage drive with pin. To assure proper Port Face
alignment, mark drive as shown. Note IDCD300S
relationship between slotted end of drive to
splined end of drive when marking. 23. With seal side of meter toward spacer plate,
align star valleys on drive. Note the parallel
relationship of reference lines A, B, C, and D.
Align bolt holes without disengaging meter from
drive.

Seal

IDCD299S

22. Install 73.5 mm [2.89 in.] ID seal in spacer plate

or gerotor (meter).

Vehicle Systems 37 Disassembly & Assembly

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 24. Install drive spacer (s) when used, in meter.

25. Install 73.5 mm [2.89 in.] ID seal in gerotor

Seal (meter) or end cap, see notes.
Drive Spacer(s)
26. Install end cap on gerotor, align holes.

IDCD301P

IDCD302P
Actual Spacer
Displacement
3

㎤/r(in/r) Length mm [in.] 27. Install 7 dry cap screws in end cap. Pretighten
45 [2.8] None screws to 11-17 N·m [100-150 lb·in] then torque
screws to specifications.
60 [3.6] None
75 [4.5] None
95 [5.9] 3.56 [.140]
120 [7.3] 6.10 [.240]
145 [8.9] 10.29 [.405]
160 [9.7] 12.19 [.480]
185 [11.3] 15.62 [.615]
230 [14.1] 21.97 [.865]
295 [17.9] 28.45 [1.120]
370 [22.6] 41.15 [1.620]
460 [28.2] 53.67 [2.113]
590 [35.9] 66.37 [2.613]
740 [45.1] 91.77 [3.613]

Vehicle Systems 38 Disassembly & Assembly

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 Brake Hydraulic Booster 1. Installation is the reverse order of removal. Be
sure to check the leakage between the
connections.
Remove and Install Brake Hydraulic
Booster 2. Remove the air (bleed the brake lines). See the
topic of Brake System Air Removal.
Flow Control Valve
3. Install the floor plate over the brake hydraulic
booster.

Brake Booster

1. Remove the floor plate.

2. Disconnect pressure line (1).

3. Disconnect the line from Flow contol valve to

Booster (2).

4. Disconnect return line (3).

5. Disconnect pressure line (4).

6. Disconnect return line (5) and brake reservoir line

(6).

7. Disconnect brake line (7).

NOTE: The following steps are for installation of the

brake master cylinder.

Vehicle Systems 39 Disassembly & Assembly

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 Disassemble & assemble brake valve

1. Take off bellows (4) and lift push rod (3), remove vent air (25) and bolts (28).

2. Separate the front housing (1) and rear housing (2), remove servo spring (10), servo piston (9) and master
piston (5).

Vehicle Systems 40 Disassembly & Assembly

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 3. Take off seal u-cup (14) from master piston (5). Notice the direction of the seal.

4. Remove lock washer (6) and ball (7) from servo piston (9). Pull off piston ring (8), seal u-cup (13), seal u-
cup (12) and seal u-cup (11) in sequence. Notice the direction of each seal.

No Color Material

11 Translucency Urethane

12 Black NBR Hs70

13 Yellow Urethane

Vehicle Systems 41 Disassembly & Assembly

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 5. Remove relief plug (18), o-ring (19), spring (17), shims (16) and piston (15) from front housing (1).

6. Remove check valve parts from rear housing (2): plug (26), o-ring (27), cage (24), spring (23), ball (21) and
o-ring (22). Remove o-ring (20).

7. Assemble brake valve in the reverse order of disassembly.

Vehicle Systems 42 Disassembly & Assembly

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 Tie Rods 6. Install the tie rod in the reverse order of removal.

Remove And Install Tie Rods

Tools Needed A B
Floor Jack 1
Drive Set 2

Start By :

a. Remove steer wheels.

NOTE: The procedure to remove and install the tie

rod is the same for each steer wheel.

1. Support the steer axle with a floor jack (A).

Position the wheel to gain access to the tie rods.

2. Remove two split pins (2). Remove pins (1).

3. Remove tie rod (4) and dust seals (3).

4. Use tooling (B) to remove bearings (5) from the

tie rod.

5. Use tooling (B) to install new bearings (5) in the

tie rod.

Vehicle Systems 43 Disassembly & Assembly

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 Steering Knuckles, Kingpins,
And Bearings

Remove And Install Steering Knuckles,

King Pins And Bearings

Tools Needed A
Drive Set 1

Start By: 4. Remove four bolts (5) and cover (6).

a. remove steer wheels

NOTE: The procedure to remove and install the

steering knuckles, kingpins, and bearings is the
same for both sides of the lift truck.

5. Remove the nut and bolt (7). For the purpose of

reassembly, the torque for bolt (7) is 11 ± 1 N•m (8
± 1 lb•ft).

1. Remove two split pins (2). Remove pin (1).

2. Position the tie rod away from the steering

knuckle.

3. Remove four bolts (3) and cover (4).

Vehicle Systems 44 Disassembly & Assembly

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 Steer Axle
Remove & Install Steer Axle

Tools Needed A
Jack Stand 4

WARNING
Be sure the pressure in the hydraulic system is
released before any lines or hoses have been
6. Remove kingpin (8) and knuckle (9). disconnected.

7. Remove spacer (11), bearing cup (13) and

bearing cone (12).
1. Put the lift truck in position on tooling (A).
8. Check the condition of lip type seal (10). Replace
seal (10) with new if worn or damaged. 2. For the purpose of reassembly, put identification
marks on hoses (1). Disconnect hoses (1). Plug
9. Repeat steps 7 and 8 for the remaining seal, and cap all openings to prevent contamination and
bearing and spacer in the other side of knuckle (9). debris from entering the system.

NOTICE
Check the condition of all seals, bearings and
components. If any parts are worn or damaged use
new parts for replacement.

10. Lubricate the pins, king pins and bearings.

11. Install the steering knuckle, kingpins and

bearings in the reverse order of removal.

End By: 3. Support the steer axle with a floor jack.

a. Install steer wheels. 4. Loosen mounting bolts (2) until approximately two
bolt threads are left in the mounting bosses.

5. Lower the steer axle onto the bolt heads with the
floor jack.

Vehicle Systems 45 Disassembly & Assembly

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 6. Remove bolts (2) and mounting caps (3) from the Steering Cylinder
steer axle.

7. Remove steer axle (4). The steer axle weighs180

Remove & Install Steering Cylinder
kg (400 lb).

NOTE : Use the following steps to install the steer

axle.

1. Remove the split (4) and pin (2) from the tie rod at
each end of steering cylinder (1).

8. Use a floor jack to position steer axle (4).

NOTE: Use bolts (2) and cap (3) to align steer axle
(4) with the mounting bosses while raising steer axle
(4) into position with the floor jack.

9. Seat steer axle (4) as follows:

a. Install bolts (2) through cap (3) and into the

mounting bosses approximately two bolt
threads.
2. Disconnect two hoses (5).
b. Use the floor jack to raise steer axle (4) into the
mounting boss. 3. Remove four bolts (3). For installation purposes,
the torque for bolts (3) is 240 ± 30 N•m (178 ± 22
c. Tighten bolts (2). lb•ft).

4. Remove steering cylinder (1).

5. Install steering cylinder (1) in the reverse order of

removal.

11. Connect hoses (1).

Vehicle Systems 46 Disassembly & Assembly

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 Disassemble And Assemble Steering
Cylinder

Start By :

a. Remove steering cylinder.

4. Remove retaining ring (5) with a plier and ring (6)

from each side of piston (7) that holds piston in
position on rod (3).

5. Remove piston (7) from the rod (3).

1. Put the steering cylinder in position in a vise.

2. Loosen head (1) from tube (2) with a spanner

wrench.

6. Remove O-ring seal (8) from the rod.

3. Remove rod assembly (3) from the tube (2).

7. Remove seal ring (9) and backup seal (10) from

the piston.

8. Loosen the head in the opposite end of the tube.

Vehicle Systems 47 Disassembly & Assembly

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 Tires And Rims (Steer)

Remove And Install Tires And Rims

(Steer)

9. Remove O-ring seal (12) and backup ring (13)

from each head (1).

1. Put a hydraulic jack in position under the steer

axle.

2. Loosen nuts (1) that hold the tire and rim in place.

3. Lift the steer axle until the tire is clear of the

ground. Remove nuts (1). Remove the tire and rim.

NOTE : The following steps are for installation of the

tires and rims (steer).
10. Remove wiper seal (14), backup ring (15), U-
packing (16) and DU-bush (17) from the bore of 4. Put the tire and rim in position on the hub.
each head.
5. Install nuts (1) that hold the tire and rim in place.
NOTE : Assemble the steering cylinder in the Tighten the nuts to a torque of 430 ± 35 NIm
reverse order of disassembly. (318 ± 25 lbIft).

6. Lower the steer axle and remove the hydraulic

jack.

Vehicle Systems 48 Disassembly & Assembly

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 Hydraulic Control Valves
Remove And Install Hydraulic Control
Valves

WARNING
Hydraulic oil under pressure can remain in the
hydraulic system after the engine and pump
have been stopped. Personal injury can result if
the pressure is not released before any work is
done to the hydraulic system. To prevent
possible personal injury, turn the engine off and
3. Support control valve (1). Remove four bolts (2),
move the control levers to make sure the
nut and control valve (1).
hydraulic pressure is released before any fitting,
plug, hose or component is loosened, tightened,
4. Install the control valve in the reverse order of
removed or adjusted. Always move the lift truck
removal.
to a clean and level location away from the travel
of other machines.
5. Fill the hydraulic tank to the correct level with fluid.
Refer to the Operation And Maintenance Manual
for further information.

NOTE : For purposes of reassembly, put

identification marks on all lines, tubes and hoses
before any disconnections are made.

1. Disconnect hydraulic lines (2) from control valve

(1).

2. Remove the cotter pins, washers and pins from

linkages.

Vehicle Systems 49 Disassembly & Assembly

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 Hydraulic Pump
Remove and Install Hydraulic Pump

Start By :

a. Remove counterweight.

1. Drain the oil from the hydraulic tank.

2. Disconnect three oil lines (1) from the pump

elbows.

3. Fasten a hoist to pump (5).

Remove bolts (4) that hold the pump in place.
Remove the pump and plate assembly.
The weight of the pump is 30 kg (132 lb).

NOTE: The following steps are for installation of the

hydraulic pump.

4. Inspect seals for damage. Install new seals, if

needed.

5. Fasten a hoist to pump (5). Put the pump and

plate assembly in position and install the bolts that
hold the pump in place. The weight of the pump is
30 kg (132 lb).

6. Connect three oil lines (1) to the pump elbows.

7. Fill the hydraulic tank with oil to the correct level.

See the Operation and Maintenance Manual.

End By :

a. Install counterweight.

Vehicle Systems 50 Disassembly & Assembly

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 General Instruction Disassembly Process
Cleanliness Rear section

1. Cleanliness is the primary means of assuring Loosen and remove the clamp bolts (18) from rear
satisfactory hydraulic pump life. working section (1).
Components such as flanges and covers are best
cleansed in soap and hot water, then air dried. Related parts
Gears should be washed in solvent, air dried, and Washer (22), Rear cover (4), Dowel pin(35),
oiled immediately. Square-ring (26).

Certain cleaning solvents are flammable. Do not

allow sources of ignition in the area when using
cleaning solvents.

2. Protect all exposed surfaces and open cavities

from damage and foreign material.
Gear journals and gear faces are super finished.
Take care not to touch these surfaces after oil and
solvent.

Lubrication of moving parts

During assembly, all running surfaces (Bearing and

wear plate) must be lightly lubricated with a clean oil 1. Remove driving gear (10), driven gear (12) with
or aerosol lubricant. thrust plate parts (8, 23, 29), keeping gear as
straight as possible, and working section (1) also.
Tools required for assembly Related parts
Back-up ring (29), O-ring (23), Thrust plate (8),
1. Socket sets Working body (1), Square ring (26).

2. Internal snap ring pliers

3. Shaft seal sleeve or clear tape

4. Torque wrench (200lbf ∙ft capacity)

5. Plastic hammer

6. Torque wrench box end adapters

Vehicle Systems 51 Disassembly & Assembly

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 Center section

4. Remove through shaft(34) from driving shaft(14).

5. Loosen and remove the clamp bolt(17) with

washer(21), and then remove the working
1. Remove through shaft (33) from driving shaft (11). section(3) from mounting flange(5)
Related parts. Square ring(25), Dowel pin (35)
2. Remove the flange(32) and the working section
(2) with dowel pin (35). Front section
Related parts
Square ring(26)

1. Remove the snap-ring (28) and shaft seal (27),

And then remove mounting flange (5) from
working section (3).

3. Remove driving gear (11), driven gear (13) with

thrust plate parts (8, 23, 29), keeping gear as
straight as possible, from first working body(3).
Related parts
Back-up ring (29), O-ring (23), Thrust plate (8).

2. Remove driving gear(14), driven gear(15) with

through shaft(34) and thrust plate parts(9,24,30)
from the working body(3), keeping gear as straight
as possible,
Related parts
Plug (19), Back-up ring (30), O-ring (24), Thrust
plate (9).

Vehicle Systems 52 Disassembly & Assembly

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 Reassembly Process Center section

Information for assembly way of thrust plates

It is important that all of thrust plate parts in this
hydraulic pump should be assembled such as below
picture during reassembly. Picture 8, 9 show
assembling sequence and direction.

1. Fit the square ring (25) on the pre-arranged

groove of the working section (3).
Smear clean grease on the square ring (25) to
avoid drifting away of square ring from the
working section (3).

(9) Thrust plate (19) Plug

(14) Driving gear (24) O-ring 2. Locate the o-ring (24) on the groove pre-arranged
(15) Driven gear (30) Back-up ring on the thrust plate (9).

Front cover area 3. Then, locate back-up ring (30) on the groove pre-
arranged on the seals (9, 24) with plug (19).
Smear clean grease on the seal(24,30)
(The front and rear thrust plates and seals and
back-up ring are same.)

1. Insert the shaft seal (27) carefully and fit it inside

of mounting flange (5) with proper tool.

2. Fit the snap-ring(28) in pre-arranged position with

proper tool.

Vehicle Systems 53 Disassembly & Assembly

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 4. Insert the driving gear (14) and driven gear (15) 8. Locate the o-ring (23) on the groove ore-arranged
into working section (3) while keeping the gears on the thrust plate (8).
straight.
Locate thrust plate(9+24+30) with care for the 9. Then, locate back-up ring (29) on the groove pre-
direction arranged on the seals (8, 23).
Smear clean grease on the seal(8,23)
(The front and rear thrust plates and seals and
back-up ring are same.)

5. Locate the completed mounting flange (5+27+28)

to working section (3) while tacking care not to
give any damage on the shaft seal by edge of
shaft(14). 10. Insert the driving shaft(11) and driven gear (13)
including the completed thrust plate(8+23+29)
6. Insert the through shaft (34) to rear side of the into working section(3) while keeping the plate
driving shaft (14). straight.

7. Tighten the bolt (17) with washer (21) in a cross

pattern to torque valve of 140Nm.

Vehicle Systems 54 Disassembly & Assembly

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 11. Insert the through shaft (33) into driving shaft 3. Locate the driving gear(10) and driven gear(12)
(11), and then locate the working body (2) and with thrust plate parts(8+23+29) into working
flange (32) after inserting the squaring ring (26) section(2).
to body (2).
Smear clean grease on the square ring (26) to 4. Insert the dowel pin(35) into the working section
avoid drifting away of square ring from the (2) and then, locate the rear working section (1) to
working body (2). working section (2) while keeping the gear straight.
Smear clean grease on the square ring (26) to
Rear section avoid drifting away of square ring from the rear
working section (1).

1. Locate the o-ring (23) on the groove pre-arranged

on the thrust plate (8). 5. Locate the rear cover(4) after inserting the
square ring(26) and the dowel pin(35) into the rear
2. Then, locate back-up ring (29) on the groove pre- working section(1).
arranged on the seals (8, 23). Smear clean grease on the square ring(26) to
Smear clean grease on the seal(8,23) avoid drifting away of square ring(26) from the
(The front and rear thrust plates and seals and rear cover(4).
back-up ring are same.)

Vehicle Systems 55 Disassembly & Assembly

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 Counterweight
Remove And Install Counterweight

6. Tighten the bolt (18) with washer (22) in a cross

pattern to torque valve of 45Nm.
Check that the pump rotate freely when the
driving shaft is turned by hand. If not a thrust plate
seal may be pinched.
1. Install two eyebolts in the counterweight. Fasten a
hoist to the eyebolts as shown.
Reference

2. Remove two bolts (1), washers that hold the

counterweight to the frame. Remove the
counterweight. The weights of the different
counterweight go from a minimum of 1830 kg
(3630 lb) to a maximum of 3120 kg (5170 lb).

NOTE: The following steps are for installation of the

counterweight.

3. Install two eyebolts in the counterweight. Fasten a

hoist to the eyebolts.

4. Put the counterweight in position on the frame

and install bolts (1), washers that hold the
counterweight in place. Tighten torque : 600 ± 50
PIC.23 Torque configuration for hydraulic pump
N•m (442 ± 37 lb•ft).

Vehicle Systems 56 Disassembly & Assembly

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 Hydraulic Oil Filter Assembly 1. Raise the machine until tires are approximately 1
to 2 inches off of the floor. Position the machine
on tooling (A).
Remove And Install Hydraulic Oil Filter
Assembly

2. Disconnect brake tubes (7) and parking cables

from drive axle.
1. Disconnect four oil lines (1).

2. Remove hydraulic tank cover (2).

3. Remove the oil filter from hydraulic tank cover.

NOTE: The following steps are for installation of the

hydraulic oil filter assembly.

4. Install the hydraulic oil filter assembly in position

on hydraulic tank cover.

5. Install the hydraulic tank cover (2) with six bolts

and washers.
3. Disconnect accel cable (8).
6. Connect four oil lines (1).
4. Disconnect wires (9) from solenoid valves and
7. Fill hydraulic oil tank to the correct level. See the wire from transmission temperature sender.
Operation and Maintenance Manual.
5. Disconnect two cooling hoses (10).
Drive Axle and T/M
6. Loosen bolts (11) and remove drive axle
Remove & Install Transaxle mounting bracket (12).

Tools Needed A B
Stand 2
Link Bracket 1

Start By :

a. Remove mast *

b. Remove floor plate.

* Refer to the mast systems Disassembly &

Assembly section for further information.

Vehicle Systems 57 Disassembly & Assembly

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 b. Install mast *

* Refer to the Mast System Disassembly &

Assembly Section for further information.

Engine
Remove & Install Engine

Tools Needed A
Link Bracket 1

7. Support the engine with a hoist and tooling (B).

NOTE: Procedures for LP gas and diesel engines
are all similar. The engine shown in the following
8. Support transaxle assembly with a floor jack and
illustrations is for diesel engine.
wood block.
Start By :

a. Remove overhead guard *

b. Remove hood (with seat) assembly *

c. Remove counterweight *

d. Remove floor plate.

e. Remove hydraulic control valve *

* Refer to the topics “Overhead Guard”, “Hood (with

seat) Assembly”, “Counterweight” and “Hydraulic
9. Remove housing cover.
Control Valve” in this module.
Remove bolts (13) that hold the converter to the
flywheel.

NOTE: At this point, make a final check to be sure

all removals and disconnections have been made
from the transaxle.

10. Remove bolts (14) and nuts from the converter

housing.

11. Use the floor jack to move transaxle assembly

from beneath the machine.

12. Install transaxle in the reverse order of removal.

1. Disconnect all hoses from radiator (3). Loosen
13. Bleed the brake system.
bolts (1) and (2) and remove radiator (3).
Refer to the topic “Brake System Air removal” in
the Testing and Adjusting section of Vehicle
Systems.

14. Fill all fluids to their correct levels.

End By :

a. Install floor plate.

Vehicle Systems 58 Disassembly & Assembly

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 2. Disconnect air intake hose (4).

3. Disconnect battery cables and remove battery (5)

and battery tray assembly.

7. Disconnect engine wire harness (8). Disconnect

wires from the alternator (9). To remove engine
from the truck, other wires or connectors not
shown should be disconnected.

4. Disconnect fuel lines from the engine.

5. Disconnect accel cable and engine stop motor

cable from the engine.

8. Remove housing cover.

Remove bolts (12) that hold the converter to the
flywheel.

NOTE: At this point, make a final check to be sure

6. Loosen nuts (6) and disconnect exhaust tube (7). all removals and disconnections have been made
from the engine.

9. Support engine with a hoist and tooling (A).

Support transaxle with wood block.

10. Remove bolts (13) and nuts from the converter

housing.

Vehicle Systems 59 Disassembly & Assembly

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 11. Remove bolts (14) and nuts from two engine
mounts, located on each side of the engine.

NOTICE
Make sure the engine is supported underneath by
suitable wooden blocks. Failure to support engine
will result in possible damage.

13. Remove the engine with a hoist.

14. Install the engine in the reverse order of removal.

End By :

a. Install hydraulic control valve *

b. Install floor plate.

c. Install hood (with seat) assembly *

d. Install counterweight *

e. Install Overhead guard.*

* Refer to the topics “Hydraulic Control Valve”,

“Hood (with seat) Assembly”, “Counterweight” and
“Overhead Guard”.

Vehicle Systems 60 Disassembly & Assembly

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